Additive manufacturing Techniques

1. Unit-4 Extrusion based &
Sheet Lamination processes
CO4: Analyze the extrusion and sheet lamination in additive Manufacturing.
Extrusion based system: FDM-Introduction-Basic Principle-Materials-
Applications and Limitations-Bioextrusion.
Sheet Lamination Process:LOM-Gluing or Adhesive bonding-Thermal bonding

2. Extrusion-Based Systems
• The material that is being extruded must be in a semisolid state when
it comes out of the nozzle.
• This material must fully solidify while remaining in that shape.
• The material must bond to material that has already been extruded
so that a solid structure can result.
• AM machine must be capable of scanning in a horizontal plane as
well as starting and stopping the flow of material while scanning.
• Once a layer is completed, the machine must index upwards, or move
the part downwards, so that a further layer can be produced.
• Molten material is liquefied inside a reservoir so that it can flow out
through the nozzle and bond with adjacent material before
solidifying.

3. Basic Principles
– Loading of material
– Liquification of the material
– Application of pressure to move the material through the nozzle
– Extrusion
– Plotting according to a predefined path and in a controlled manner
– Bonding of the material to itself or secondary build materials to form a
coherent solid structure
– Inclusion of support structures to enable complex geometrical features

4. Material Loading
• Material Loading extrusion is used, there must be a chamber from
which the material is extruded.
• The chamber itself is therefore the main location for the liquification
process. Pellets, granules, or powders are fed through the chamber
under gravity or with the aid of a screw or similar propelling process.
• Materials that are fed through the system under gravity require a
plunger or compressed gas to force it through the narrow nozzle.
• Screw feeding not only pushes the material through to the base of the
reservoir but can be sufficient to generate the pressure needed to
push it through the nozzle as well.
• A continuous filament can be pushed into the reservoir chamber, thus
providing a mechanism for generating an input pressure for the nozzle.

5. Liquification
• The extrusion method works on the principle that what is held in the
chamber will become a liquid that can eventually be pushed through
the die or nozzle.
• This material could be in the form of a solution that will quickly
solidify following the extrusion, but more likely this material will be
liquid because of heat applied to the chamber.
• The material inside the chamber should be kept in a molten state but
care should be taken to maintain it at as low a temperature as
possible since some polymers degrade quickly at higher temperatures
and could also burn, leaving residue on the inside of the chamber that
would be difficult to remove and that would contaminate further
melt.

6. Schematic of extrusion-based systems
• The extrusion nozzle determines the shape and size of the
extruded filament. A larger nozzle diameter will enable
material to flow more rapidly but would result in a part with
lower precision compared with the original CAD drawing.
The diameter of the nozzle also determines the minimum
feature size that can be created. No feature can be smaller
than this diameter and in practice features should normally
be large relative to the nozzle diameter to faithfully
reproduce them with satisfactory strength. Extrusion-based
processes are therefore more suitable for larger parts that
have features and wall thicknesses that are at least twice
the nominal diameter of the extrusion nozzle used. Material
flow through the nozzle is controlled by the pressure drop
between the chamber and the surrounding atmosphere.
Pinch roller feed system is used this is most common
approach, one can consider the forces generated by the
rollers as the mechanism for generating the extrusion
pressure.
The increased modulus would lead to higher pressure and
thus a higher force generated by the pinch rollers.

7. Materials
• ABS (acrylonitrile butadiene styrene)
• The most popular material is the ABSplus material, which can be used
on all current Stratasys FDM machines.
• This is an updated version of the original ABS (acrylonitrile butadiene
styrene) material that was developed for earlier FDM technology.
• Users interested in a translucent effect may opt for the ABSi material,
which has similar properties to other materials in the ABS range.
Some machines also have an option for ABS blended with
Polycarbonate (PC).